Flow line installation device for drilling rigs

ABSTRACT

A pipe installation device for a drilling rig includes a frame that is pivotably coupled to an elevated rig floor of the drilling rig, a saddle coupled to the frame and configured to grip a pipe, and a driver coupled to the frame and the elevated rig floor of the drilling rig. The driver is configured to cause the frame to pivot from a first configuration in which the saddle is configured to support the pipe in a substantially vertical orientation to a second configuration in which the saddle is configured to support the pipe in a substantially horizontal orientation for connection to a well device.

BACKGROUND

Drilling rigs are machines that drill wells, e.g., oil and gas well. Drilling rigs may include a substructure that supports an elevated rig floor and a mast over a well center. Drilling equipment may be located on the rig, including on the floor and the mast, and may be configured to run a drill string (including a drill bit, drill pipes, and potentially various other equipment) into the ground, thereby forming and extending the wellbore.

Various types of equipment may be located below the rig floor, e.g., between bases boxes of the substructure, such as a blowout preventer (BOP) that controls fluid flow into and/or out of the wellbore. For example, mud may flow into the drill string, and may be circulated through the drill string, and back up to the BOP through the annulus between the drill string and the wellbore. The mud may be used to control the pressure in the wellbore, lubricate the drill bit, remove cuttings, etc.

The mud that circulates back up through the BOP may be delivered into mud tanks. Various mud treatment devices, e.g., shakers, separators, etc. may be provided to condition the mud for re-use in the well. The mud may then be stored and/or pumped back into the well. Large diameter pipes may be employed to direct the mud from the BOP to the mud tanks, providing a “flow line” from the BOP to the mud tanks. The flow line generally extends horizontally or at a slight downward angle to facilitate the flow of the mud from the BOP to the mud tanks.

Drilling rigs may be assembled, used, and then disassembled at a wellsite. Large equipment may be called for to conduct such assembly processes, including cranes, for example, to hoist the large diameter, horizontal pipes of the flow line for assembly with the BOP and mud tanks. Such equipment may be rented, and thus the cost associated therewith may be directly related to the amount of time that the equipment is onsite. Accordingly, it may be desirable to reduce the process that rely on such cranes.

SUMMARY

This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

Embodiments of the disclosure may provide a pipe installation device for a drilling rig. The pipe installation device includes a frame that is pivotably coupled to an elevated rig floor of the drilling rig, a saddle coupled to the frame and configured to grip a pipe, and a driver coupled to the frame and the elevated rig floor of the drilling rig. The driver is configured to cause the frame to pivot from a first configuration in which the saddle is configured to support the pipe in a substantially vertical orientation to a second configuration in which the saddle is configured to support the pipe in a substantially horizontal orientation for connection to a well device.

Embodiments of the disclosure may also provide a method for installing a pipe on a drilling rig. The method includes securing the pipe in a substantially vertical orientation in a saddle coupled to a rig floor via a frame, pivoting the frame relative to the rig floor so as to rotate the pipe to a substantially horizontal orientation, and coupling the pipe in the substantially horizontal orientation to a well device, such that the pipe is configured to communicate fluid to or from the well device while the pipe is in the substantially horizontal orientation.

Embodiments of the disclosure may further provide a drilling rig. The drilling rig includes an elevated rig floor, a well device positioned at least partially below the rig floor and proximal to a first side of the rig floor, a mud tank positioned at least partially below the rig floor and proximal to a second side of the rig floor, a flow line extending in a substantially horizontal orientation from the well device to the mud tank, and an installation device. The installation device includes a frame that is pivotably coupled to the elevated rig floor, a saddle coupled to the frame and configured to receive and grip a pipe, and a driver coupled to the frame and the elevated rig floor of the drilling rig. The driver is configured to cause the frame to pivot from a first configuration in which the saddle is configured to support the pipe in a substantially vertical orientation to a second configuration in which the saddle is configured to support the flow line in the substantially horizontal orientation.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present teachings and together with the description, serve to explain the principles of the present teachings. In the figures:

FIG. 1 illustrates a perspective view of a drilling rig, according to an embodiment.

FIG. 2 illustrates a side, elevation view of a portion of the drilling rig, including a flow line installation device, according to an embodiment.

FIG. 3 illustrates a side, elevation view of a portion of the drilling rig, showing the flow line being loaded into the installation device, according to an embodiment.

FIG. 4 illustrates a side, elevation view of the portion of the drilling rig of FIG. 3, showing the installation device pivoting the flow line into a substantially horizontal position, according to an embodiment.

FIG. 5 illustrates a side, elevation view of the portion of the drilling rig, showing another embodiment of the installation device maneuvering the flow line into position for connection to the blowout preventer (BOP).

FIG. 6 illustrates a side, elevation view of the portion of the drilling rig, showing the flowline being loaded into a third embodiment of the installation device.

FIG. 7 illustrates a side, elevation view of the portion of the drilling rig, showing the third embodiment of the flowline being pivoted to a substantially horizontal orientation and translated into connection with the BOP, according to an embodiment.

FIG. 8 illustrates a flowchart of a method for installing a flow line in a drilling rig, according to an embodiment.

DETAILED DESCRIPTION

Reference will now be made in detail to specific embodiments illustrated in the accompanying drawings and figures. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the embodiments described herein. However, it will be apparent to one of ordinary skill in the art that embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

It will also be understood that, although the terms “first”, “second”, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are used to distinguish one element from another. For example, a first object could be termed a second object, and, similarly, a second object could be termed a first object, without departing from the scope of the present disclosure.

The terminology used in the description of the techniques herein is for the purpose of describing particular embodiments and is not intended to be limiting. As used in the description of the techniques herein and the appended claims, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including,” “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Further, as used herein, the term “if” may be construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context.

FIG. 1 illustrates a perspective view of a drilling rig 100, according to an embodiment. The drilling rig 100 may include a rig floor 102, which may be elevated above the ground by a substructure 103. The substructure 103 may include, for example, a pair of base boxes 106 (only one is visible). The drilling rig 100 may additionally include a well device, e.g., a blowout preventer (BOP) 104, which may be positioned below the drilling rig 100.

The drilling rig 100 may further include a mast 110, which may extend upwards from the rig floor 102. A pipe rack 112 may be coupled to the mast 110 and configured to support an upper end of drill pipes that may be stored on the rig 100. A catwalk 114 may also be provided, e.g., for loading tubulars from a horizontal orientation at the ground to a substantially vertical orientation at the rig floor 102. A driller's side cabin 120 may further be provided on the rig floor 102. An off-driller's side cabin may also be provided, in some embodiments.

FIG. 2 illustrates a side, elevation view of a portion of the drilling rig 100, according to an embodiment. As shown, the drilling rig 100 includes the rig floor 102, including an off-driller side cabin 122, and the BOP 104. A rotating control device (RCD) 105 may be positioned on top of the BOP 104 and may be configured to rotatable seal with a drill string or another tubular extending therefrom. In some embodiments, the RCD 105 may be omitted, in which case a riser is connected from the top of the BOP to a catch can connected to the bottom of the drill floor 102. The BOP 104, RCD 105, and catch can may each be considered a “well device” for purposes of this disclosure.

Further, a flow line 200 may extend between the RCD 105 and a mud tank 201. In embodiments in which the RCD 105 is omitted, the flow line 200 may instead extend between the catch can and the mud tank 201. For purposes of this description, the flow line 200 will be described, as illustrated, extending from the RCD 105. As shown, the flow line 200 may extend in a generally horizontal orientation, e.g., between about horizontal and about 10 degrees to the ground, below the elevated rig floor 102. The flow line 200 may be configured to be coupled to the BOP 104 on one end and to a mud tank 202 on the other end, with the RCD 105 and the mud tank 202 being on different sides of the elevated rig floor 102, as shown. The drilling rig 100 may also include a choke manifold 203, which may include various chokes, valves, etc., for managed pressure drilling (MPD). The flow line 200 may extend past the choke manifold 203, e.g., at least partially above the choke manifold 203, as shown. The flow line 200 may thus be configured to receive drilling mud from the BOP 104 and provide the drilling mud to the mud tank 201, e.g., via gravity. The mud tank 201 may include various skids, shakers, pumps, etc. configured to store and/or prepare the mud for recirculation into the well.

The flow line 200 may be supported in the substantially horizontal orientation by an installation device 210. For example, the installation device 210 may be coupled to the elevated rig floor 102, e.g., so as to be able to pivot (“pivotable”) with respect thereto. In an embodiment, the installation device 210 may include a frame 212, a saddle 214, and a driver 216. The frame 212 may be pivotably coupled to the rig floor 102, e.g., via one or more pins, bearings, etc. located at a pivot point 217. In a specific embodiment, the installation device 210 may include a brace 218, which extend downward and parallel to the rig floor 102, with the pivot point 217 being located at a distal end of the brace 218.

The driver 216 may be coupled to the frame 212 and configured to extend and retract, so as to pivot the frame 212 with respect to the rig floor 102 and with respect to the driver 216 itself, as will be described in greater detail below. For example, the driver 216 may be an extensible hydraulic cylinder, but a variety of other electric, mechanical, pneumatic, hydraulic or other types of drivers could be employed. In an embodiment, the driver 216 may be coupled to the brace 218, and positioned between the brace 218 and the rig floor 102.

The saddle 214 may be coupled to the frame 212, and may be configured to receive and grip the flow line 200. For example, the saddle 214 may include at least two connections 215A, 215B that are separated axially apart for connection to the flow line 200. The provision of at least two connections 215A, 215B may facilitate control of the rotational orientation of the flow line 200 via the installation device 210, e.g., preventing the flow line 200 from pivoting with respect to the saddle 214.

Once received into the saddle 214, the flow line 200 may be supported from the rig floor 102 via the frame 212 across a range of orientations, e.g., between substantially vertical and substantially horizontal. As the term is used herein, “substantially vertical” refers to perpendicular to the ground within a reasonable tolerance, e.g., plus or minus 10 degrees. For example, the connections 215A, 215B of the saddle 214 may include latches, clamps, slips, or any other device configured to grip a tubular member, such as the flow line 200. In an embodiment, the flow line 200 may include a collar 220, which may be configured to couple with the saddle 214 so as to secure the flow line 200 into connection with the saddle 214. The collar 220 may be located a sufficient distance from a lower end 230 of the flow line 200 to provide clearance from the ground when the flow line 200 is supported in the installation device 210.

FIG. 3 illustrates a side, elevation view of a portion of the drilling rig 100, depicting an initial stage of operation of the installation device 210, according to an embodiment. As shown, the flow line 200 may be initially held in a substantially vertical orientation and loaded into the installation device 210 in a first configuration. A crane or another type of lifting device (e.g., material handler or forklift) may be employed to hoist the flow line 200 initially from the ground, and then move the flow line 200 vertically (with respect to the ground) and potentially in a horizontal direction as well into engagement with the saddle 214 on a first side 300 of the rig floor 102, opposite from the BOP 104, for example. The crane may then lower the flow line 200 until the collar 220 lands on the connection 215A. The saddle 214 may then secure onto the flow line 200, e.g., an operator 302 positioned on the rig floor 102 may engage a latching mechanism of the saddle 214. Once the flow line 200 is secured, the crane may release the flow line 200, such that the flow line 200 is supported in the substantially vertical orientation from the rig floor 102 via the frame 212 and the saddle 214.

FIG. 4 illustrates a side, elevation view of a portion of the drilling rig 100, illustrating another aspect of operation of the installation device 210, e.g., after the initial operation of FIG. 3, according to an embodiment. In this embodiment, the driver 216 may be energized (provided with energy), e.g., extended, causing the frame 212 to pivot (clockwise, as shown) about the pivot point 217 to a second configuration. Accordingly, the saddle 214 is also pivoted, which in turn rotates the flow line 200 from the substantially vertical orientation to the substantially horizontal position, as shown by dashed lines. In the substantially horizontal position, the lower end 230 of the flow line 200 may be coupled to the RCD 105, for example, by extending a pipe slide/coupling 402 or otherwise bridging the gap between the lower end 230 and the RCD 105.

FIG. 5 illustrates a side, elevation view of a portion of the drilling rig 100, showing the installation device 210 according to another embodiment. As shown, the installation device 210 includes the frame 212, saddle 214, and driver 216, and is configured to pivot the frame 212, and thus the flow line 200, about the pivot point 217 from the substantially vertical orientation to the substantially horizontal position, e.g., by extending the driver 216, as discussed above. In addition, the installation device 210 includes a second driver 500, which may be located on the saddle 214. The second driver 500 may be configured to translate the flow line 200 with respect to the frame 212, and thus to move the flow line 200 in a substantially horizontal direction, toward or away from the RCD 105, relative to the rig floor 102 and without moving the frame 212. For example, the second driver 500 may be an extensible hydraulic cylinder, as shown, but gear drives or other mechanical, electrical, pneumatic, or hydraulic devices could be used. The provision of the second driver 216 may allow for omitting the extensible pipe slide 402 at the lower end 230 of the flow line 200, instead allowing the entire flow line 200 to be moved toward the RCD 105 for coupling therewith.

FIG. 6 illustrates a side, elevation view of a portion of the drilling rig 100, showing another embodiment of the installation device 210. In this embodiment, the installation device 210 includes the frame 212, saddle 214, and driver 216, supported from the rig floor 102 via the brace 218. Further, a carriage 600 is coupled to the frame 212, and provides the pivot point 217 between the frame 212 and the carriage 600. The carriage 600 is movable along a generally path that extends at least partially in a horizontal direction (horizontally or at an acute angle to horizontal), e.g., as defined by the brace 218. The driver 216 may operate to push or pull the frame 212 along this path.

In addition, the installation device 210 may include a support arm 602. The support arm 602 may be pivotally coupled to the rig floor 102 at a second pivot point 604. The support arm 602 may also be pivotally coupled to the flow line 200, e.g., at a position that is axially offset from, e.g., above, the connection 215A of the saddle 214, at a second pivot point 606. The support arm 602 may prevent free-swinging of the flow line 200 until the driver 216 retracts, at which point, the support arm 602 may swing through an arc, at the same time that the saddle 214 swings through an arc, thereby reorienting the flow line 200 from the substantially vertical orientation of FIG. 6 to the substantially horizontal position of FIG. 7. Like the embodiment with the second driver 500 discussed above with reference to FIG. 5, the carriage 600 gives the installation device 210 the ability to move the flow line 200 in a horizontal direction and into connection with the BOP 104, while still clearing the BOP 104 during rotation of the flow line 200 from vertical to substantially horizontal.

FIG. 8 illustrates a flowchart of a method 800 for installing a pipe on a drilling rig, according to an embodiment. In at least some embodiments, the method 800 may be executed using the drilling rig 100 and the flow line 200 (as the pipe), although other embodiments may employ other structures. Further, the worksteps of the method 800 discussed herein may be performed in any suitable order, two or more worksteps may be combined into one, one workstep may be divided into two or more separate worksteps, and/or any of the worksteps may be performed in parallel, without departing from the scope of the present disclosure.

The method 800 may include securing the pipe 200 in a substantially vertical orientation in a saddle 214 coupled to a rig floor 102 via a frame 212, as at 802. Securing the pipe 200 in the substantially vertical orientation in the saddle 214 may include, for example, lifting the pipe 200 using a crane, and then lowering the pipe 200 in the substantially vertical orientation. Lowing the pipe 200 may cause a collar 220 of the pipe 200 to be landed onto a connection 215A of the saddle 214. The collar 220 may be positioned such that a lower end 230 of the pipe 200 is elevated from the ground, and the lower end 230 of the pipe 200 does not contact the BOP 104 when the pipe 200 is rotated to the substantially horizontal orientation.

The method 800 may also include pivoting the frame 212 relative to the rig floor 102 so as to rotate the pipe 200 to a substantially horizontal orientation, as at 804. Pivoting the frame may include energizing a driver 216 coupled to the rig floor 102 and to the frame 212. For example, the driver 216 may be or include a hydraulic cylinder, and energizing the driver 216 may include extending the hydraulic cylinder.

In an embodiment, the method 800 may also include moving the pipe 200 in a horizontal direction, toward the RCD 105, after securing the pipe 200 in the saddle 214, as at 806. For example, a second driver 500 coupled to the saddle 214 may be energized, such that the saddle 214 is moved relative to the frame 212 and/or relative to the rig floor 102 in the horizontal direction. In another example, moving the frame 212 in the horizontal direction may be accomplished by retracting the driver 216 coupled to a carriage 600 of the frame 212, which causes the frame 212 and a support arm 602 pivotably coupled to the rig floor 102 and the pipe 200 to pivot about respective pivot points 217, 604. In some embodiments, moving the pipe 200 in the horizontal direction may be accomplished before, during, or after rotating the pipe 200 from the substantially vertical orientation to the substantially horizontal orientation.

The method 800 may further include coupling the pipe 200 in the substantially horizontal orientation to a well device (e.g., an RCD 105, catch can, or another device), such that the pipe 200 is configured to communicate fluid to or from the well device while the pipe 200 is in the substantially horizontal orientation, as at 808. In an embodiment, the well device may be a an RCD 105, and the pipe 200 may be a mud flow line 200 that extends from the RCD 105 to a mud tank 201. Coupling the pipe 200 to the RCD 105 may, in some embodiments, include extending a pipe slide 402 from the lower end 230 of the pipe 200 to the RCD 105, or from the RCD 105 to the lower end 230 of the pipe 200.

The pipe 200 may be retained in the horizontal position indefinitely, while the rig 100 is in operation. When it is desired to disassemble the rig 100, the method 800 may be reversed, such that the pipe 200 is detached from the RCD 105, pivoted back to its substantially vertical orientation, and then removed from connection with the installation device 210 via a crane.

The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. Moreover, the order in which the elements of the methods described herein are illustrate and described may be re-arranged, and/or two or more elements may occur simultaneously. The embodiments were chosen and described in order to explain at least some of the principals of the disclosure and their practical applications, to thereby enable others skilled in the art to utilize the disclosed methods and systems and various embodiments with various modifications as are suited to the particular use contemplated. 

What is claimed is:
 1. A pipe installation device for a drilling rig, comprising: a frame that is pivotably coupled to an elevated rig floor of the drilling rig; a saddle coupled to the frame and configured to grip a pipe; and a driver coupled to the frame and the elevated rig floor of the drilling rig, wherein the driver is configured to cause the frame to pivot from a first configuration in which the saddle is configured to support the pipe in a substantially vertical orientation to a second configuration in which the saddle is configured to support the pipe in a substantially horizontal orientation for connection to a well device.
 2. The pipe installation device of claim 1, wherein the pipe comprises a mud flow line configured to communicate with a mud tank when the pipe is in the substantially horizontal orientation, and wherein the well device comprises a rotating control device.
 3. The pipe installation device of claim 1, wherein, when the frame is in the first configuration, the saddle is positioned on a first side of the elevated rig floor, and wherein the pipe in the substantially horizontal orientation is positioned at least partially beneath the elevated rig floor.
 4. The pipe installation device of claim 1, wherein the driver comprises an extensible hydraulic cylinder, the frame being configured to pivot by extending the hydraulic cylinder.
 5. The pipe installation device of claim 1, further comprising a pipe slide that is extendably coupled to the pipe, wherein the pipe slide is configured to extend to connect together the well device and the pipe.
 6. The pipe installation device of claim 1, wherein the frame is configured to slide or roll relative to the elevated floor, so as to translate the pipe in an at least partially horizontal direction toward or away from the well device.
 7. The pipe installation device of claim 6, further comprising a support arm pivotally coupled to the elevated rig floor and to the pipe, wherein the frame comprises a carriage that is constrained to horizontal movement and is coupled to the driver, wherein the driver is configured to retract to rotate the pipe, the support arm, and the frame relative to the rig floor.
 8. The pipe installation device of claim 1, further comprising a second driver configured to move the saddle relative to the rig floor, so as to move the pipe in the substantially horizontal orientation toward the well device.
 9. A method for installing a pipe on a drilling rig, comprising: securing the pipe in a substantially vertical orientation in a saddle coupled to a rig floor via a frame; pivoting the frame relative to the rig floor so as to rotate the pipe to a substantially horizontal orientation; and coupling the pipe in the substantially horizontal orientation to a well device, such that the pipe is configured to communicate fluid to or from the well device while the pipe is in the substantially horizontal orientation.
 10. The method of claim 9, wherein the well device comprises a rotating control device, and wherein the pipe comprises a mud flow line that extends from the rotating control device to a mud tank.
 11. The method of claim 9, wherein securing the pipe in the substantially vertical orientation in the saddle comprises lifting the pipe using a lifting device, and then lowering the pipe in the substantially vertical orientation.
 12. The method of claim 11, wherein securing the pipe in the saddle further comprises landing a collar of the pipe onto a connection of a saddle, wherein the collar is positioned such that a lower end of the pipe is elevated from a ground, and the lower end of the pipe does not contact the well device when the pipe is rotated to the substantially horizontal orientation.
 13. The method of claim 9, wherein pivoting the frame comprises energizing a driver coupled to the rig floor and to the frame.
 14. The method of claim 13, wherein the driver comprises a hydraulic cylinder, wherein energizing the driver extends the hydraulic cylinder.
 15. The method of claim 9, further comprising moving the pipe in a substantially horizontal direction, toward the well device, after securing the pipe in the saddle.
 16. The method of claim 15, wherein moving the pipe in the substantially horizontal direction comprises energizing a second driver coupled to the saddle.
 17. The method of claim 9, further comprising moving the pipe in a substantially horizontal direction toward the well device while rotating the frame.
 18. The method of claim 17, wherein moving the pipe in the substantially horizontal direction while rotating the frame comprises moving the frame in a linear direction by retracting a driver coupled to a rolling carriage of the frame, wherein retracting the driver causes the frame and a support arm pivotably coupled to the rig floor and the pipe to pivot about respective pivot points.
 19. The method of claim 9, wherein coupling the pipe to the well device comprises extending a pipe slide from a lower end of the pipe to the well device, or from the well device to the lower end of the pipe.
 20. A drilling rig, comprising: an elevated rig floor; a well device positioned at least partially below the rig floor and proximal to a first side of the rig floor; a mud tank positioned at least partially below the rig floor and proximal to a second side of the rig floor; a flow line extending in a substantially horizontal orientation from the well device to the mud tank; and an installation device comprising: a frame that is pivotably coupled to the elevated rig floor; a saddle coupled to the frame and configured to receive and grip a pipe; and a driver coupled to the frame and the elevated rig floor of the drilling rig, wherein the driver is configured to cause the frame to pivot from a first configuration in which the saddle is configured to support the pipe in a substantially vertical orientation to a second configuration in which the saddle is configured to support the flow line in the substantially horizontal orientation. 